Wiring system architecture

ABSTRACT

A new wiring and power and communications system for an automobile that includes a plurality of devices, wherein the devices are connected to a backbone section that has an outer sheathing, a first conductor disposed within the outer sheathing, a second conductor disposed within the outer sheathing, a pair of inner sheathing members disposed within the outer sheathing and located on opposing sides of the at least one conductor, the inner sheathing members configured to electrically insulate the first conductor from the second conductor, and a shield member disposed within the outer sheathing.

CROSS REFERENCE TO RELATED PATENTS

The present U.S. Utility patent application claims priority pursuant to35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/618,681,entitled “WIRING SYSTEM ARCHITECTURE”, filed Jan. 18, 2018, which ishereby incorporated herein by reference in its entirety and made part ofthe present U.S. Utility patent application for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND Technical Field

The present disclosure relates to a new wiring and power andcommunications distribution system. More particularly, the presentdisclosure relates to a wiring system for an automobile.

Description of Related Art

Traditional car wiring for vehicles are piecemeal solutions. Typically,there are different wiring harnesses that connect each differentelectrical component to a central battery or power source. Eachcomponent receives power, but requires multiple wiring harnesses forcommunication and signals. The total length of the wire may be manymiles within a single vehicle. These wiring harnesses typically consistof multiple round conductors that are not rigid. Round conductors arenot optimal for transmitting current and the lack of rigidity oftraditional wiring harnesses requires assembly into the vehicle usinghuman hands, which can be a slow process. Further, connecting eachcomponent to the central battery is not optimized on an automobilelevel.

Hence, there is a need for wires and a wiring-system architecture thatovercomes the aforementioned drawbacks.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a illustrates a top view of an automobile showing a body and awiring system for connecting a plurality of devices to a backboneaccording to certain embodiments of the current invention.

FIG. 1b illustrates a top view of an automobile showing a body and awiring system for connecting a plurality of endpoints to a backboneaccording to certain embodiments of the current invention.

FIG. 2 illustrates a subassembly with devices connected to the backbonesection via an umbilical cable according to embodiments of the presentdisclosure.

FIGS. 3-6 e illustrate different cross-sections of the backbone sectionthat could be implemented in the wiring system according to certainembodiments of the current invention.

FIG. 6f illustrates a cross-section of an umbilical cable that could beimplemented in the wiring system for connecting with the backbonesection of FIG. 6c according to certain embodiments of the currentinvention.

FIG. 7 illustrates a different cross-section of the backbone sectionthat could be implemented in the wiring system according to certainembodiments of the current invention.

FIG. 8a illustrates a perspective view of a pair of sections associatedwith the backbone section that are configured to be mutually connectedwith the help of an interconnect system according to certain embodimentsof the current invention.

FIG. 8b illustrates a zoomed-in perspective view of the interconnectsystem showing pins on a first section and receptacles on a secondsection of the backbone section according to certain embodiments of thecurrent invention.

FIG. 9 illustrates sections of a backbone showing an interconnect systemwith cylindrical pins and receptacles according to certain embodimentsof the current invention.

FIGS. 10a-10b illustrate a section of a backbone showing an interconnectsystem in which polygonal pins are encased in an overmold bridgeaccording to certain embodiments of the current invention.

FIGS. 11a-11f illustrate different configurations of backbone sectionsand interconnect systems used to connect the backbone sections accordingto certain embodiments of the current invention.

FIGS. 12a-12d illustrate yet another interconnect system according to acertain embodiment of the current invention.

FIGS. 13a-13b illustrate exploded and assembled views of an interconnectsystem having an adapter for connecting backbone sections according tocertain embodiments of the current invention.

FIG. 14 is an exploded view of a backbone with an interconnect systemfor connecting a pair of backbone sections according to certainembodiments of the current invention.

FIGS. 15a-15b illustrate exploded and assembled views of a wiringsystem, according to certain embodiments of the current invention.

FIG. 16 illustrates a backbone section with a compound washer accordingto a certain embodiment of the current invention.

FIG. 17a illustrates a compound washer according to a certain otherembodiment of the current invention.

FIG. 17b is an exploded view of a backbone section employing thecompound washer of FIG. 17a and a flex plate, according to a certainother embodiment of the current invention.

FIG. 17c illustrates connected backbone sections using the compoundwasher of FIG. 17a according to a certain other embodiment of thecurrent invention.

FIG. 18a illustrates a backbone section with windowed regions to make aconnection to another cable according to certain embodiments of thecurrent invention.

FIG. 18b illustrates an umbilical cable with windowed regions to make aconnection to the backbone section or another cable, via the PCBA,according to certain embodiments of the current invention.

FIGS. 19a-d illustrate the backbone connector according to certainembodiments of the current invention.

FIGS. 20a-b illustrate the backbone connector according to certainembodiments of the current invention.

FIG. 21-24 illustrates the installation procedure of connecting abackbone section to an umbilical cable using a backbone connectoraccording to an embodiment of the current invention.

FIG. 25 illustrates a cross section view of the backbone connectoraccording to an embodiment of the current invention.

FIGS. 26-28 illustrate the backbone connector according to certainembodiments of the current invention.

FIGS. 29-31 illustrate the backbone connector according to certainembodiments of the current invention.

Embodiments of the present disclosure and their advantages are bestunderstood by referring to the detailed description that follows. Itshould be appreciated that like reference numerals are used to identifylike elements illustrated in one or more of the figures, whereinshowings therein are for purposes of illustrating embodiments of thepresent disclosure and not for purposes of limiting the same.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure relates to a wiring-system architecture and thecables and connectors necessary to implement the architecture. Theoverall wiring system disclosed herein approaches wiring in a differentmanner than traditional automotive wiring architectures. Traditionalautomotive wiring architectures often have many miles of cables snakingfrom centralized controllers and power sources to devices through thevehicle. This new architecture reduces the number and length of cables,and moves certain controllers into subassemblies which then control oneor multiple devices present in the vehicle. To achieve power and signaltransmission, new cables and connectors have been created and describedherein.

In this new wiring architecture, subsystems are packaged and defined inone or multiple assemblies in certain embodiments. For example, a doorassembly might contain one controller (or hub) that controls multipledevices, such as locking components, lighting components, audiocomponents, etc. In addition to decreasing the number and length ofwiring needed, the ability to create these subassemblies and thenconnect them to the wiring-architecture backbone will decrease assemblytime during general assembly, which is very desirable to increaseproductivity in a vehicle manufacturing process. The subassembly may becreated ahead of general assembly with only the connection between thedoor subassembly and subsystem made and verified during generalassembly.

Embodiments of the present disclosure are directed at achieving theforegoing objectives.

Reference will now be made in detail to specific aspects or features,examples of which are illustrated in the accompanying drawings. Whereverpossible, corresponding or similar reference numbers will be usedthroughout the drawings to refer to the same or corresponding parts.

Wiring Architecture

FIG. 1a illustrates a top view of an automobile 100 having a body 102and a wiring system 104 for connecting a plurality of devices 106disposed on the body 102 to a central processor 108 located within thebody 102. The wiring system 104 includes a backbone 112 that is used toconnect devices 106 to a central battery 180 as shown in FIG. 1b . Thebattery 180 may also be located elsewhere. Devices 106 may be sensors,motors, modules, actuators, or another device. These devices 106 may bedirectly connected to the backbone 112 as shown in FIG. 1a , or theremay be intermediate connections, connectors, and/or printed circuitboard assemblies in between.

FIG. 1b illustrates a top view of an automobile 100 having a body 102and a wiring system 104 for connecting a plurality of endpoints 186disposed on or within the body 102 to a central battery 180. As shown,the wiring system 104 is formed of multiple backbone sections 112.Although multiple backbone sections 112 are depicted in the illustratedembodiment of FIG. 1b , it will be appreciated that in other embodimentsof this invention, the wiring system 104 could be formed of a singlebackbone section 112. Wiring system 104 may also be located towards thecenter of the car, and may not necessarily follow the periphery or sidesof the car 100 or car body 102. Backbone sections 112 are connected tobattery 180. Battery 180 may be a 12V battery. In other embodiments,battery 180 may operate at a higher voltage, such as 40V or 48V or 60 V.Umbilical cables 184 are connected to a backbone section 112 via abackbone connector 190. Backbone connector 190, in different embodimentsof the wiring system 104, may not be present allowing an umbilical cable184 to be directly connected to backbone 112. Each umbilical cable 184may be typically connected to a hub 252 containing a printed circuitboard assembly (PCBA) 254, as shown in FIG. 2. In certain embodiments,the umbilical cable 184 need not necessarily be connected to amicrocontroller that may reside on the PCBA 254. In fact, in certainother embodiments, the umbilical cable 184 may not even be connected tothe hub 252, the PCBA 254, or the microcontroller residing on the PCBA254, rather, the umbilical cable 184 may be directly connected to adevice, for example, the device 106 a, 106 b, or 106 c shown in FIG. 2.

PCBAs may be located within a subassembly, such as a seat, door, orother assembly that may be added or removed from the vehicle framebefore, during, or after general assembly. When the umbilical cable 184is connected to a PCBA, such as the PCBA 254, it is preferentially hotbar soldered to the PCBA, although the umbilical cable 184 may also beconnected to the PCBA in other manners, such as, by means of a connectorthat is described later herein, by laser soldering, by traditionalconnectors, ultrasonic soldering, or by using conductive adhesives. ThePCBA 254 is then connected to tentacle cables 286 that ultimatelyterminate in a device, such as the device 106 a, 106 b, or 106 c shownin FIG. 2. Preferentially, the PCBA 254, the tentacle cables 286, andthe devices 106 are packaged together to form part of an assembly, suchas the subassembly 250 shown in FIG. 2. Multiple subassemblies 250 maybe assembled together, as one larger subassembly, with one subassemblyhosting the hub 252 as well as the PCBA 254 and remaining subassemblieshaving only the PCBA 254. These assemblies, or portions thereof, can bemanufactured separately and then assembled into or with the vehicleframe during general assembly. In an example of a door assembly, thedevices 106 a, 106 b, 106 c could include a mirror movement actuatingmechanism and/or and a door locking mechanism. If so, the mirrormovement actuating mechanism and the door locking mechanism may each beconnected to the PCBA, such as the PCBA 254 using tentacle cables, suchas, the tentacle cables 286 shown in FIG. 2. This way, productivity canbe increased during the general assembly process as manufacturers ofautomobiles can do away with the time-consuming processes that used tobe performed earlier for accomplishing wiring in automobiles.

It may be noted that the tentacle cables 286 disclosed herein may havethe same structure as the backbone section 112, or may have a differentnumber of conductors or conductor geometry in order to appropriatelyconnect to a device, such as the device 106 a, 106 b, or 106 c, or ahub, such as the hub 252 or other hubs 259 a or 259 b exemplarily shownin FIG. 2. In FIG. 2, the hub 252, which includes the PCBA 254, isconnected to each of the devices 106 a, 106 b, and 106 c as well as eachof the two hubs 259 a and 259 b. These hubs 259 a, 259 b may be embodiedas a USB type or any other type of hub known to persons skilled in theart. Also, as disclosed earlier herein, in certain embodiments, thedevices 106 could include sensors and span, generally, a wide array offeatures and functionality. It is hereby contemplated thatalternatively, or additionally, in certain embodiments, the devices 106could include a mirror actuator, a seat actuator, a power lock actuator,or any other device known for actuating one or more functions within thevehicle.

Backbone and Backbone-to-Backbone Connections

In certain embodiments, backbone sections 112 are structural cables.Structural cables may be of the type disclosed in U.S. Pat. App.62/484,198, entitled “Structural Cable,” which is herein incorporated byreference. In other embodiments, the backbone sections 112 may have across section as shown in any one of the FIGS. 3-5. Backbone sections112 may also be another type of cable with structural support or a cablewithout structural support. In certain embodiments, backbone sections112 have the cross section as shown in FIGS. 6a-6e or FIG. 7. Thesestructural cables may be connected to one another. In certainembodiments, backbone sections 112 lack structure. In certainembodiments, backbone sections are made using conductive ink, conductivecoatings, conductive paint, or conductive adhesive applied directlyapplied to car body 102 to form the wiring system 104.

FIG. 3 illustrates a cross-sectional view of the backbone section 112according to a certain embodiment of the present disclosure. As shown inFIG. 3, the backbone section 112 has an outer sheathing member 124within which a bus bar 126 and a pair of conductors 128 a and 128 b arelocated. In certain other embodiments, the backbone section 112 may notcontain the bus bar 126. As shown in FIG. 3, each of the conductors 128a, 128 b is disposed alongside the bus bar 126 and located in aspaced-apart relation to one another.

A pair of inner sheathing members 130 a, 130 b are located outside ofthe conductors 128 a, 128 b. The inner sheathing members 130 a, 130 belectrically insulate each of the conductors 128 a, 128 b from the busbar 126. The outer sheathing member 124 and the inner sheathing members130 may be made of non-conductive materials. The material(s) used toform the outer sheathing member 124 and each of the inner sheathingmembers 130 may be similar or dissimilar. Example materials that couldbe used to form the outer and inner sheathing members 124, 130 includepolyethylene (PE), polyimide (PI), polypropylene (PP), polyethyleneterephthalate (PET), polyethylene naphthalate (PEN), or anotherinsulating material. Various other suitable thermoplastic polymerscommonly known to persons skilled in the art may be used to formrespective ones of the outer and inner sheathing members 124, 130disclosed herein.

A pair of conductive shield members 132 a, 132 b are also within theouter sheathing member 124 and located on opposing sides of the pair ofinner sheathing members 130 a, 130 b and the conductors 128 a and 128 brespectively. These conductive shield members 132 reduce electromagneticfields in a space adjoining each of the conductors 128 a, 128 b and/orthe bus bar 126 by blocking the electromagnetic fields produced by oneor more of the conductors 128 a, 128 b and the bus bar 126 respectively.The conductive shield members 132 may be made from an electricallyconductive material such as copper (Cu) or Aluminum (Al), and may haveadhesive as well as non-conductive materials pre-attached to the Cu orAl. The conductive shield members 132 may also contact on both sides ofconductors 128, fully wrapping conductors 128.

In certain embodiments, the bus bar 126, the pair of conductors 128, thepair of inner sheathing members 130, and the pair of conductive shieldmembers 132 are parallel or substantially parallel to one another and ina stacked configuration within the outer sheathing member 124 of thebackbone section 112. The stacked configuration of the bus bar 126, thepair of conductors 128, the pair of inner sheathing members 130, and thepair of conductive shield members 132 helps to render a compact form tothe backbone section 112. This way, an amount of space required toaccommodate the backbone section 112, for instance, when tight spaceconstraints are encountered may be minimized.

The bus bar 126 and the conductors 128 are configured to transmit poweror data signals to the different endpoints 186, hubs 252, 259, and/ordevices 106 (refer to these components in FIGS. 1a, 1b , and 2). Forinstance, the bus bar 126 could transmit power while the conductors 128may transfer data signals. In other embodiments, the conductors 128 maytransmit power, and the bus bar 126 may be only structural in functionor may be omitted from the backbone section 112. In embodiments, if thebus bar 126 or a conductor 128 carries power or data signals, thecomponent has a line impedance in the range of 5-125 Ohms, single-endedor differential. For instance, it is envisioned that the bus bar 126 andeach of the conductors 128 a, 128 b of the backbone section 112 depictedin the cross-sectional view of FIG. 3 could be configured to exhibit animpedance of 10Ω (Ohms). In other embodiments, each of the bus bar 126and the conductors 128 a, 128 b may be configured to exhibit or offer animpedance of 50Ω (Ohms).

FIGS. 4-7 illustrate additional cross sections of the backbone section112 according to certain embodiments. As shown, each backbone section112 contains a bus bar 126. This bus bar 126 may be removed in certainembodiments. In the embodiment shown in FIGS. 4-7, four conductors 128a-128 d are present. In certain embodiments, the bus bar 126 and each ofthe conductors 128 a-128 d may have an impedance of 20Ω (Ohms). Incertain other embodiments, the bus bar 126 and each of the conductors128 a-128 d may exhibit an impedance of 100Ω (Ohms). Impedance can takea variety of forms and be odd even, common, or differential.

Further, in different embodiments, the thickness of the inner sheathingmembers 130 a, 130 b may be similar or dissimilar. For example, in thebackbone section 112 of FIG. 4, a thickness T of the inner sheathingmember 130 b associated with the conductors 128 a, 128 b is similar to athickness T of the inner sheathing member 130 b associated with theconductors 128 c, 128 d. However, in another example as shown in FIG. 5,the thicknesses T₁ of the inner sheathing members 130 a, 130 bassociated with the pair of conductors 128 a and 128 b differ from thethicknesses T₂ of the inner sheathing members 130 a, 130 b associatedwith the pair of conductors 128 c, 128 d respectively. Therefore, it maybe noted that the thicknesses of the inner sheathing members 130 a, 130b may be varied during manufacture of the backbone section 112 to suitspecific requirements of an application.

FIGS. 6a-6e and 7 illustrate additional cross sections of the backbonesection 112 according to certain embodiments. In certain embodiments,cross sections of one or more conductors 128 a-d may be dissimilar. Asshown in FIGS. 6a-6e and 7, the cross-sections associated with theconductors 128 c, 128 d is smaller and hence, dissimilar to thatassociated with the conductors 128 a-128 b respectively. In otherembodiments, the cross-section of the conductors 128 a-128 d can besimilar to one another. Additional conductors (not shown) may also beadded in addition to 128 a-128 d, and may be added in the same plane, oralternatively, above or below conductors 128 a-128 d.

Moreover, as shown in FIGS. 6a and 7, a pair of inner sheathing members130 a, 130 b are outside of conductors 128 a, 128 b. These conductors128 c and 128 d are shielded by a conductive shield member 132 thatsurrounds the pair of inner sheathing members 130 a, 130 b. Multipleconductive shield members 132 may exist within the backbone section 112.For example, more conductors (not shown) alongside conductors 128 may beadded, and may also include a conductive shield member 132. Theconductors 128 a and 128 b may carry power while the conductors 128 cand 128 d may carry data signals. An insulating sheathing layer 130 mayadditionally be present as shown in the view of FIG. 6a . One or moreadhesive layers may also be present. FIG. 6a shows two adhesive layers410 a and 410 b. An adhesive layer adheres the backbone section 112 tothe vehicle, or another desired location. In other embodiments, asealing layer 140 (also referred to herein as an outer sheating memberor outer sheating material) might exist around the conductors 128 a-128d and the insulating sheathing layer 130. FIG. 6a shows sealing layer140 that seals the conductors 128 a-128 d from dust and/or water vapor.When present, the adhesive layer 410 a and 410 b may be inside thesealing layer 140 (that is, part of the sealing layer 140 could be onthe vehicle or component to which the backbone section 112 is adhered).Alternatively, the adhesive layers 410 a and 410 b may be outside of thesealing layer 140.

In embodiments, conductors 128 a-128 d carry voltages of 6V or less. Inother embodiments, one or more conductors 128 a-128 d carry voltages ofgreater than 5V, for example, one conductor might carry a voltage ofapproximately 10V, another a voltage of approximately 100V, while thirdand fourth conductors carry a voltage of approximately 5V.

FIG. 6b illustrates a cross-section of a backbone section 112 inaccordance with certain embodiments of the present disclosure. Thebackbone section 112 includes conductors 128 a-128 d. A non-conductiveinner sheathing member 130 insulates one or more of conductors 128 a-128d. In embodiments, the inner sheathing member 130 surrounds twoconductors. In other embodiments, the inner sheathing member 130surrounds fewer or more than two conductors. Inner sheathing member 130is necessary to insulate a conductor from shielding layer 131 ifshielding layer is present around a conductor. As shown in FIG. 6b ,conductors 128 c, 128 d are surrounded by inner sheathing member 130.The inner sheathing member 130 is formed from an insulating material,such as polyethylene (PE), polyimide (PI), polypropylene (PP),polyethylene terephthalate (PET), polyethylene naphthalate (PEN), oranother insulating material. Various other suitable thermoplasticpolymers commonly known to persons skilled in the art may be used toform the inner sheathing member 130 disclosed herein. Conductiveshielding layer 131 surrounds and abuts inner sheathing member 130. Inembodiments, conductive shielding layer 131 surrounds fewer or more thantwo conductors. Conductive shielding layer 131 may be made from Cu, Al,or another conductive metal, and may be plated (or otherwise covered)with Sn, Ni, Au, or another conductive material. In embodiments,conductive shielding layer 131 is formed from a non-conductive materialand plated (or otherwise covered) with a conductive material, such asCu, Al, Sn, Ni, Au, another metal, or another conductive material.

FIG. 6c illustrates a cross-section of a backbone section 112 inaccordance with certain embodiments of the present disclosure. Thebackbone section 112 includes conductors 128 a-r. The sets of conductors128 a-b, and 128 c-d may exhibit similarity of configuration andfunction with that disclosed in conjunction with embodiments herein.Conductors 128 c-d and 128 e-f are surrounded by the inner sheathingmember 130 and the conductive shielding layer 131. Inner sheathingmember 130 may fully encase conductors, as shown in FIG. 6c , oralternatively, inner sheathing member 130 may be disjointed and exhibitan open configuration whereby it is not continuous and includes voidregions.

In the embodiments described in this disclosure, conductors 128 e-f and128 g-r may be formed from the same material, or alternatively, they maybe formed from dissimilar material. For example, each conductor from thesets of the conductors 128 e-f and 128 g-r may be copper while eachconductor from the sets of conductors 128 a-b and 128 c-d may bealuminum. In certain situations, certain of conductors 128 a-b and 128c-d are used to transmit data in the form of control and/or feedbacksignals between devices, for example, a PCBA 196 (shown in FIGS. 19a-d), a processing unit, or control functionality, and a safety device (notshown) within the automobile 100 (refer to FIGS. 1a-b ). Such safetydevice may be an airbag, but is not limited thereto.

Further, conductors 128 e-f and 128 g-r may transmit data in one or bothdirections between devices. For example, conductors 128 e-f may transmitcontrol signals from PCBA 196 (or another location) to one or moresafety devices, while conductors 128 g-r may transmit feedback signalsfrom the safety devices to a central processor, control functionality,or another location. In another example, conductors 128 e-f and 128 g-rmay be capable of transmitting data bi-directionally between devices,for instance, a central processor or control functionality and thesafety device.

Each conductors 128 e-f may have the same cross sectional dimensions(width and height), or may have different cross sectional dimensions.For example, the width and height of each conductors 128 a-b may be aspecific width and height, while conductors 128 e-f are only 50-80% ofthe of the width and height of conductors 128 a and/or 128 b. Similarly,the thickness of the inner sheathing member 130 associated with the setof conductors 128 e-f may be similar or dissimilar to the thickness ofthe inner sheathing member 130 surrounding the conductors 128 c-d. Whendissimilar thicknesses are present, the inner sheathing member 130surrounding conductors 128 e-f may be thicker or thinner than thethickness of inner sheathing member 130 surrounding conductors 128 c-d.Further, the dimensions of conductors 128 g-r may be the same ordifferent than the dimension of conductors 128 e-f. The dimensions andmaterial of the conductors 128 a-b, 128 c-d, 128 e-f, and 128 g-r may beselected depending on the function the conductors are to perform, forexample, transmitting control and/or feedback signals.

FIGS. 6d and 6e illustrate additional embodiments backbone section 112.As depicted in FIG. 6d , unshielded conductor 128 a is not present(compared to FIG. 6c ). That is two shielded conductors 128 c-d andunshielded conductor 128 a are present. In addition, conductors 128 g-rare also present and conductors 128 e-f are not present (compared toFIG. 6c ). In the embodiment shown in FIG. 6e , the backbone section 112includes shielded conductors 128 c-d and unshielded conductor 128 a.

FIG. 6f illustrates a cross-section of an umbilical cable 184 that canbe connected to the backbone section 112 of FIG. 6c , via the PCBA 196(refer to FIGS. 19a-d ). The umbilical cable 184 illustrates a similarconfiguration of the conductors that are included within the backbonesection 112 of FIG. 6c . The major difference is that fewer conductors128 g-r are present, specifically only conductors 128 g-h are present.When conductors 128 g-h are used to transmit signals from a safetydevice, the umbilical cable need only contain two of conductors 128 g-h,while the backbone section 112 must include more conductors so that itmay carry signals from other connected umbilical cables. For example, asshown in FIG. 6c , the backbone section has twelve conductors 128 g-r,while the umbilical cable 184 has two conductors 128 g-h, as shown inFIG. 6 f.

The twelve conductors 128 g-r within the backbone section (as shown, forexample, in FIG. 6c ), may be grouped into pairs, for example,conductors 128 g-h, 128 i-j, 128 k-1 and so on, and establishconnections to multiple safety devices via multiple different umbilicalcables 184. For example, with the twelve conductors 128 g-r shown in thebackbone section 112 of FIG. 6c , six umbilical cables 184, as shown inFIG. 6f can be connected to the backbone section 112, with eachumbilical cable later connected to a safety device and used to transmitsignals from the safety device to a processing unit or controlfunctionality. In certain embodiments, umbilical cables 184 includesmore than one pair of conductors, for example, two pairs of conductors128 g-h and 128 i-j. In other embodiments, the backbone section 112includes fewer or more conductors than those shown in FIG. 6c tofacilitate connections with more or fewer safety devices.

FIG. 8a illustrates an exploded view of the backbone section 112 with aninterconnect system 800 consisting of pins 802 and receptacles 804connecting a first backbone section 112 a and a second backbone section112 b. Each backbone section 112 a, 112 b may be located adjacent andconnected to one another with the help of the interconnect system 800.As shown, the interconnect system 800 includes pins 802 that aredisposed on the first backbone section 112 a and receptacles 804disposed on the second backbone section 112 b.

FIG. 8b illustrates a zoomed-in view of interconnect system 800 fromFIG. 8a showing the pins 802 a-802 h from the first backbone section 112a and the receptacles 804 a-804 h from the second backbone section 112b. As shown, each pin 802 is connected (usually physically andelectrically) with one of the bus bar 126, one or more conductors 128a-128 d, or one or more conductive shield members 132 a-132 b (refer toFIG. 5) of the first section 112 a of the backbone section 112 shown inFIG. 8a . For instance, pin 802 a may be connected to the bus bar 126(refer to FIG. 5) that is part of the first section 112 a, while pins802 b, 802 c, 802 d, and 802 e may be connected to conductors 128 a, 128b, 128 c, and 128 d (refer to FIG. 5) of the first section 112 a of thebackbone section 112 shown in FIG. 8 a.

Moreover, pins 802 f, 802 g may be connected to conductive shieldmembers 132 a and 132 b which provide shielding for conductors 128 a-b,and 128 c-d (refer to FIG. 5) respectively, offering a continuouselectrical return path for data signals. Further, pin 802 h may beconnected to conductive shield member 132 b (refer to FIG. 5) of thefirst section 112 a of the backbone section 112 (refer to FIGS. 8a-8b ).

Further, as shown in FIGS. 8a-8b , the interconnect system 800 alsoincludes receptacles 804 that are on an end portion of the secondsection 112 b (although they could be anywhere along the secondsection). These receptacles 804 are configured to accept pins 802, thatis, the size and shape of the receptacle opening accept pins 802. Forinstance, the receptacle 802 a may be connected with the bus bar 126 ofthe second section 112 b and hence, connects the bus bar 126 of thefirst section of the first section 112 a through accepting pin 802 a.Similarly, receptacles 804 b, 804 c, 804 d, and 804 e are connected tothe conductors 128 a, 128 b, 128 c, and 128 d of the second section 112b and connected to conductors 128 a, 128 b, 128 c, and 128 d of thefirst section 112 a though pins 802 b, 802 c, 802 d, and 802 erespectively. The pins 802 and receptacles 804 may take alternateshapes, materials, and geometries beyond cylindrical profiles, and pins802 and receptacles 804 of varying shapes, materials, and geometries mayco-exist.

Also, with continued reference to FIGS. 5 and 8 b, some portion of theouter sheathing member 124 may be stripped-off to define additionalreceptacles 804 f, 804 g, and 804 h. The receptacles 804 f and 804 g maybe connected to conductive shield members 132 a (refer to FIG. 5) thatare connected to conductors 128 a-b and 128 c-d respectively. Further,the receptacle 804 h may be connected to conductive shield member 132 b.These receptacles 804 f, 804 g, and 804 h would be configured to acceptpins 802 f, 802 g, and 802 h respectively (refer to FIG. 8b ) and formthe desired connection between the first and second sections 112 a, 112b.

In certain embodiments, the interconnect system 800 may be stabilizedwith the help of a cumulative force from radial pressure of anengagement between a tubular wall 806 containing each receptacle 804 andits corresponding pin 802 when engaged to one another. That is, theengagement between each pin 802 and the tubular wall 806 of receptacle804 would be snug such that a radial force would apply to hold the pin802 into the receptacle 804 and create a contact between the two. Thepins 802 and receptacles 804 may also be welded as necessary to increasestrength at the connection point.

FIG. 9 shows an exploded view of a backbone section 112 with a firstsection 112 a and a second section 112 b connected together according toa certain embodiment of the present disclosure. As shown, the firstsection 112 a includes a bus bar 902 a and a pair of conductors 904 a,904 b that are disposed successively over the bus bar 902 a of the firstsection 112 a. Similarly, the second section 112 b includes a bus bar902 b and a pair of conductors 904 c, 904 d that are disposedsuccessively over the bus bar 902 b of the second section 112 b. Aninterconnect system 900 for connecting the first and second sections 112a, 112 b includes three pins 908 a-c located on the first section 112 aand three receptacles 910 a-c located on the second section 112 b. Thepin 908 a is connected to the bus bar 902 a of the first section 112 awhile the pins 908 b, 908 c are connected to the pair of conductors 904a, 904 b associated with the first section 112 a. Likewise, receptacle910 a is connected to the bus bar 902 b of the second section 112 bwhile the receptacles 910 b, 910 c are connected to the pair ofconductors 904 c, 904 d associated with the second section 112 b. Pins908 a, 908 b, and 908 c are configured to engage with receptacles 910 a,910 b, and 910 c respectively. In the illustrated embodiments of FIG. 9,it may be noted that each of the pins 908 and receptacles 910 arecylindrically shaped so that these cylindrically-shaped pins 908 andreceptacles 910 correspond with one another to facilitate a mutualengagement of the pins 908 to the receptacles 910. The connection methodbetween pins 908 and receptacles 910 may comprise of inductivesoldering, press-fitting, brazing, wave soldering, or be conductiveadhesive based. Further, it may also be noted that strips of conductivematerial/s forming each of the bus bars 902 a, 902 b, and each of theconductors 904 a-d may also be disposed laterally with respect tocorresponding ones of each of the bus bars 902 a-b, and each of theconductors 904 a-d so that power and/or data signals can be transferredin a direction laterally away from one or more points that are locatedpartway along a length of the first and second sections 112 a, 112 b ofthe backbone section 112.

According to another embodiment shown in FIGS. 10a-10b , the firstsection 112 a of the backbone section 112 includes pins 1002, forinstance, pins 1002 a-1002 f that are polygonal in shape, and other pins1002, for instance, pin 1002 g that are cylindrical in shape. Moreover,in additional embodiments, pins 1002 are shown partially encased in anovermold bridge 1006 formed of a non-conducting material, for example,epoxy, acrylic, silicone rubber, or other polymer base material, such aspolybutylene terephthalate (PBT). As best shown in FIG. 10b , the secondsection 112 b defines some receptacles 1004, for instance, receptacles1004 a-f that are polygonal in shape, and other receptacles 1004, forinstance, receptacle 1004 g that is cylindrical in shape. Each ofreceptacle 1004 from the second section 112 b is configured to connectto corresponding pin 1002 from the first section 112 a. The bridge 1006can be adhered to the second section 112 b with the help of a gasket1008 that could include, for example, a cure-in-place (CIP) gasket or aform-in-place (FIP) as known to persons skilled in the art, forattachment as well as sealing purposes. The gasket 1008 may also beovermolded over the bridge 1006. As shown best in FIG. 10a , the gasket1008 is applied to a surface 1006 a of the bridge 1006 facing the secondsection 112 b so that the gasket 1008 helps the bridge 1006 to adherewith the second section 112 b of the backbone section 112 and therefore,stabilize the interconnect system 1000 upon engagement of the pins 1002to their corresponding receptacles 1004.

Referring to FIG. 11a , a backbone section 112 according to anembodiment of the present disclosure includes a first half 1101 a and asecond half 1101 b. Moreover, as shown in FIG. 11a , first and secondhalves 1101 a, 1101 b are stacked on top of one another. The first half1101 a includes a bus bar 126 a and a conductor 128 a that is stackedaround the bus bar 126 a with an inner sheathing member 130 a positionedbetween the bus bar 126 a and the conductor 128 a. Likewise, the secondhalf 1101 b includes a bus bar 126 b and a conductor 128 b that isstacked around the bus bar 126 b with an inner sheathing member 130 bpositioned between the bus bar 126 b and the conductor 128 b. Aninterconnect system 1102 is provided to connect the first and secondhalves 1101 a, 1101 b to another backbone section. As shown in theillustrated embodiment of FIG. 11a , the interconnect system 1102includes bridging conductors, bridging shield, and insulating layers(1120 a, 1120 b, 1120 c, 1122 b, 1122 c), that serve to connect the busbars and conductors in the first and second halves 1101 a, 1101 b tocorresponding halves in another backbone section.

Referring to FIG. 11b , a backbone section 112 according to anembodiment of the present disclosure includes a first half 1101 a, and asecond half 1101 b that is placed in a stacked configuration withrespect to the first half 1101 a. As shown, the first and second halves1101 a, 1101 b are identical to one another and are placed symmetricallyabout a parting line ‘P’. The first half 1101 a includes three bus bars126 a, 126 b, 126 c and a conductor 128 a. As shown, the conductor 128 ais disposed about the bus bar 126 c. Further, the first half 1101 a alsoincludes three outer sheathing members 124 a, 124 b, 124 c and an innersheathing member 130 a. The outer sheathing members 124 a, 124 b, 124 care configured to insulate the bus bars 126 a, 126 b and the conductor128 a respectively while the inner sheathing member 130 a is configuredto mutually insulate the bus bar 126 c and the conductor 128 a from oneanother.

Similarly, the second half 1101 b includes three bus bars 126 d, 126 e,126 f and a conductor 128 b. As shown, the conductor 128 b is disposedabout the bus bar 126 f. Moreover, the second half 1101 b also includesthree outer sheathing members 124 d, 124 e, 124 f and an inner sheathingmember 130 b. The outer sheathing members 124 d, 124 e, 124 f areconfigured to insulate the bus bars 126 d, 126 e and the conductor 128 brespectively while the inner sheathing member 130 b is configured tomutually insulate the bus bar 126 f and the conductor 128 b from oneanother. An interconnect system 1104 is provided to connect the firstand second halves 1101 a, 1101 b to other backbone sections. As shown,the interconnect system 1104 includes bridging conductors, bridgingshield, and insulating layers (1130 a, 1130 b, 1130 c, 1130 d, 1132 a,1132 b, 1132 c), that serve to connect the bus bars and conductors inthe first and second halves 1101 a, 1101 b to corresponding halves inanother backbone section.

Referring to FIGS. 11c-11d , a backbone section 112 according to anotherembodiment of the present disclosure includes a first half 1101 a and asecond half 1101 b that is placed in a stacked configuration withrespect to the first half 1101 a. As shown, the first and second halves1101 a, 1101 b are identical to one another. However, the first andsecond halves 1101 a, 1101 b are asymmetrical to one another about aparting region ‘P’. The first half 1101 a includes three bus bars 126 a,126 b, 126 c and a conductor 128 a. As shown, the conductor 128 a isdisposed about the bus bar 126 c. Further, the first half 1101 a alsoincludes three outer sheathing members 124 a, 124 b, 124 c and an innersheathing member 130 a. The outer sheathing members 124 a, 124 b, 124 care configured to insulate the bus bars 126 a, 126 b and the conductor128 a respectively while the inner sheathing member 130 a is configuredto mutually insulate the bus bar 126 c and the conductor 128 a from oneanother.

Similarly, the second half 1101 b includes three bus bars 126 d, 126 e,126 f and a conductor 128 b. As shown, the conductor 128 b is disposedabout the bus bar 126 f. Moreover, the second half 1101 b also includesthree outer sheathing members 124 d, 124 e, 124 f and an inner sheathingmember 130 b. The outer sheathing members 124 d, 124 e, 124 f areconfigured to insulate the bus bars 126 d, 126 e and the conductor 128 brespectively while the inner sheathing member 130 b is configured tomutually insulate the bus bar 126 f and the conductor 128 b from oneanother.

An interconnect system 1106 is provided to connect the first and secondhalves 1101 a, 1101 b. The interconnect system 1106 includes bridgingconductors, bridging shield, and insulating layers (1140 a, 1140 b, 1142a, 1144 a, 1144 b, 1146 a, 1146 b), that serve to connect the bus barsand conductors in the first and second halves 1101 a, 1101 b tocorresponding halves in another backbone section.

Referring to FIG. 11e , a backbone section 112 according to anembodiment of the present disclosure may include a first half 1101 a,and a second half 1101 b that is stacked on top of the first half 1101a. The first and second halves 1101 a, 1101 b are asymmetrical aboutregion ‘P’. The first half 1101 a includes three bus bars 126 a, 126 b,126 c and a conductor 128 a. As shown, the conductor 128 a is disposedabout the bus bar 126 c. Further, the first half 1101 a also includesthree outer sheathing members 124 a, 124 b, 124 c and an inner sheathingmember 130 a. The outer sheathing members 124 a, 124 b, 124 c areconfigured to insulate the bus bars 126 a, 126 b and the conductor 128 arespectively while the inner sheathing member 130 a is configured tomutually insulate the bus bar 126 c and the conductor 128 a from oneanother.

Similarly, the second half 1101 b includes three bus bars 126 d, 126 e,126 f and a conductor 128 b. As shown, the conductor 128 b is disposedabout the bus bar 126 f. Moreover, the second half 1101 b also includesthree outer sheathing members 124 d, 124 e, 124 f and an inner sheathingmember 130 b. The outer sheathing members 124 d, 124 e, 124 f areconfigured to insulate the bus bars 126 d, 126 e and the conductor 128 brespectively while the inner sheathing member 130 b is configured tomutually insulate the bus bar 126 f and the conductor 128 b from oneanother. An interconnect system 1108 is provided to connect the firstand second halves 1101 a, 1101 b to another backbone section andincludes bridging conductors, bridging shield, and insulating layers.

Referring to FIG. 11f , a backbone section 112 according to anotherembodiment includes a first half 1101 a and a second half 1101 b thatare placed in a stacked configuration. The first and second halves 1101a, 1101 b are placed symmetrically about a parting line ‘P’. The firsthalf 1101 a includes three bus bars 126 a, 126 b, 126 c and a conductor128 a. As shown, the conductor 128 a is disposed about the bus bar 126c. The bus bars 126 a, 126 b are stacked successively and disposedalongside the bus bar 126 c. Further, the first half 1101 a alsoincludes three outer sheathing members 124 a, 124 b, 124 c and an innersheathing member 130 a. The outer sheathing members 124 a, 124 b, 124 care configured to insulate the bus bars 126 a, 126 b and the conductor128 a respectively while the inner sheathing member 130 a is configuredto mutually insulate the bus bar 126 c and the conductor 128 a from oneanother.

Similarly, the second half 1101 b includes three bus bars 126 d, 126 e,126 f and a conductor 128 b. As shown, the conductor 128 b is disposedabout the bus bar 126 f. The bus bars 126 d, 126 e are stackedsuccessively and disposed alongside the bus bar 126 f. The second half1101 b also includes three outer sheathing members 124 d, 124 e, 124 fand an inner sheathing member 130 b. The outer sheathing members 124 d,124 e, 124 f are configured to insulate the bus bars 126 d, 126 e andthe conductor 128 b respectively while the inner sheathing member 130 bis configured to mutually insulate the bus bar 126 f and the conductor128 b from one another. An interconnect system 1110 connects the firstand second halves 1101 a, 1101 b to another backbone section. As shown,the interconnect system 1110 includes an interconnect member 1160 thatis tiered in shape. The interconnect member 1160 includes multiplestepped portions 1160 a, 1160 b, 1160 c, and 1160 d.

FIGS. 12a-12d illustrate various components of a backbone 1200 accordingto certain embodiments. Referring to FIGS. 12c-12d , the backbonesection 1200 includes a first section 1202 and a second section 1204that are connected to one another. As shown, the first section 1202includes a first bar 1202 a and the second section 1204 includes asecond bar 1204 a. Each of these bars 1202 a, 1204 a is of a rectangularcross-section. In an embodiment, a backbone section 112 according to anyof the embodiments shown in FIGS. 8a-8b , FIGS. 10a-10b , and each ofthe FIGS. 11e-11f could be used to form each of the first and secondbars 1202 a, 1202 b respectively. However, if a backbone section 112from any of the foregoing embodiments is not required, for instance,when the wiring system 104 is used to only establish power connectionsbetween electrical and/or electronic components that are kept apart fromone another, then in such cases, the first and second bars 1202 a, 1202b could be made from an electrically non-conductive material. Therefore,depending on specific requirements of an application, one skilled in theart could use the backbone section 112 according to any of theembodiments shown in FIGS. 8a-8b , FIGS. 10a-10b , and each of the FIGS.11e-11f as the first and second bars 1202 a, 1202 b in the backbone1200, or use electrically non-conductive materials for the first andsecond bars 1202 a, 1202 b. According to the embodiment illustrated inFIGS. 12a-12d , each of the first and second bars 1202 a, 1202 b is madefrom an electrically non-conductive material.

As shown in FIG. 12d , the backbone section 1200 also includes fourconductors 1208 a, 1208 b, 1208 c, and 1208 d. Although four conductors1208 a-1208 d are disclosed, in other configurations of the backbone1200, the number of conductors 1208 used in the backbone 1200 can varydepending on specific requirements of an application. For example, sixconductors may be used—three conductors on each of the bars 1202 a, 1204a. In an exemplary configuration of the backbone 1200 shown in FIG. 12d, two of the four conductors 1208 a, 1208 b are associated with thefirst section 1202 while the remaining two conductors 1208 c, 1208 d areassociated with the second section 1204. Each of these conductors 1208a-1208 d includes an electrical wire 1210 whose end 1210 a is exposed toan exterior of the associated conductor 1208 a-1208 d by stripping-off aportion of an insulating sheathing member 1212 within which the end 1210a of the wire 1210 was previously located. Moreover, the insulatingsheathing member 1212 associated with wires 1210 of the conductors 1208could be affixed to associated bars 1202 a, 1204 a, for example, by useof an adhesive (not shown).

The backbone 1200 includes an interconnect system 1206. According tothis embodiment, the interconnect system 1206 comprises terminals 1214a-1214 d could be soldered to ends 1210 a of the wires 1210 fromrespective ones of the conductors 1208 a-120 d. As shown, each of theseterminals 1214 a-d is formed preferably from thin, stamped sections ofmetal sheets (for example, metal sheet having thickness in the range of0.1 millimeter-5 millimeters). Moreover, each of these terminals 1214a-d could be either laid out on an associated bar (as shown forterminals 1214 c-1214 d on the first bar 1202 a in FIG. 12a ), or bentover edges bounding an end portion of an associated bar (as shown forthe terminals 1214 a-1214 b that partially enclose the end portion ofthe second bar 1202 a in FIG. 12b ).

According to an embodiment shown in FIG. 12d , the backbone 1200 alsocomprises holes 1216 a, 1216 b that are defined on the bars 1202 a, 1202b of the first and second sections 1202, 1204 respectively. The holes1216 a, 1216 b may be sized and shaped to allow use of a securingarrangement 1218 for securing the bars 1202 a, 1204 a of the twosections 1202, 1204, and also to secure the interconnect system 1206between the bars 1202 a, 1204 a of the two sections 1202, 1204 so thatthe terminals 1214 a, 1214 b on the first bar 1202 a can be maintainedin contact with respective ones of the terminals 1214 c, 1214 d on thesecond bar 1204 a.

To form the backbone 1200, the sections 1202, 1204 are positioned suchthat the hole 1216 a on the first bar 1202 a is in alignment with thehole 1216 on the second bar 1204 a while the terminals 1214 a, 1214 b onthe first bar 1202 a are in abutment with respective ones of theterminals 1214 c, 1214 d on the second bar 1202 b as shown in FIG. 12d .The securing arrangement 1218 can then be used to engage with themutually aligned holes 1216 a, 1216 b for securing the first and secondbars 1202 a, 1204 a with one another. According to an embodiment asshown in FIG. 12d , the securing arrangement 1218 includes a bolt 1220that can be received in the mutually aligned holes 1216 a, 1216 b of thefirst and second bars 1202 a, 1204 a and a nut 1222 that can releasablyengage with the bolt 1220. Although, the bolt 1220 and nut 1222 isdisclosed herein, it will be appreciated by persons skilled in the artthat other types of securing arrangements may be used in lieu of thebolt 1220 and nut 1222 disclosed herein for securing the first andsecond bars 1202 a, 1204 a. Therefore, the bolt 1220 and nut 1222 shouldnot to be construed as being limiting of this disclosure. Rather, theterms “securing arrangement” disclosed herein could extend in scope toinclude other types of arrangements for securing the two bars 1202 a,1204 a including, but not limited to, adhesion bonding, soldering,crimping or other methods of securement typically known to personsskilled in the art.

FIG. 13a-13b illustrate exploded and assembled views of interconnectsystem 1300 according to another embodiment. The interconnect systemincludes an adapter 1302 that can be used to secure a pair of sections1304, 1306 carrying conductors 1304 a-1304 b and 1306 a-1306 brespectively. The adapter 1302 includes a first portion 1302 a that isaffixed to the first bar 1304, and a second portion 1302 b that isaffixed to the second bar 1306. When coupled to one another, the firstand second portions 1302 a, 1302 b could establish a mating joint therebetween such that the conductors 1304 a-1304 b on the first section 1304can be connected to respective ones of the conductors 1306 a-1306 b onthe second section 1306.

FIG. 14 illustrates a backbone 1400 having an interconnect system 1401that includes an adapter 1402 according to another embodiment. In thisembodiment, the adapter 1402 includes a first portion 1402 a that isaffixed to a first bar 1404 and a second portion 1402 b that is affixedto a second bar 1406. The adapter 1402 also includes an intermediateportion 1402 c which is configured to engage with each of the first andsecond portions 1402 a, 1402 b respectively.

Referring to FIGS. 15a-15b , a backbone 1500 according to anotherembodiment. A first bar 1502 is configured to define a conductingsurface 1502 a that is disposed on an end portion of the first bus bar1502, and a non-conducting surface 1502 b that is located on a remnantportion of the first bus bar 1502. Similarly, a second bus bar 1504 isconfigured to define a conducting surface 1504 a that is disposed on anend portion of the second bus bar 1504, and a non-conducting surface1504 b that is located on a remnant portion of the second bus bar 1504.The non-conducting surfaces 1502 b, 1504 b of the first and second busbars 1502, 1504 may be obtained by coating the portions remnant orexclusive of the conducting portions 1502 a, 1504 c from the respectivebus bars 1502, 1504 with an electrically insulating layer of material/scommonly known to persons skilled in the art. Exemplary material/sinclude silicone polyethylene complex polymers, which can be malleableas well as retain form, homopolymer high density polyethylene (HDPE),which can achieve good plastic deformation retention, or anotherpolymer. To form specific bends and geometries, localized heat may beused to thermoplastically deform the polymer as long as they may beformed or deformed for covering the desired structure of the associatedbus bar 1502, 1504.

The first bus bar 1502 includes a first pair of holes 1508 a, 1508 bwhile the second bus bar 1504 is configured to define a second pair ofholes 1510 a, 1510 b that correspond to respective ones of the firstpair of holes 1508 a, 1508 b of the first bus bar 1502. Each hole fromthe first pair of holes 1508 a, 1508 b extends from the conductingsurface 1502 a to the non-conducting surface 1502 b located on anopposing side 1501 a to the conducting surface 1502 a of the first busbar 1502. Likewise, each hole from the second pair of holes 1510 a, 1510b extends from the conducting surface 1504 a to the non-conductingsurface 1504 b located on an opposing side 1501 b to the conductingsurface 1504 a of the second bus bar 1504. As best shown in FIG. 15b ,when the first and second bus bars 1202, 1204 are assembled to form thebackbone 1500, the conducting surfaces 1502 a, 1504 a from the first andsecond bus bars 1502, 1504 are positioned in abutment with one anotherwhile the first pair of holes 1508 a, 1508 b are positioned in alignmentwith the second pair of holes 1510 a, 1510 b.

Additionally, a di-electric spacer 1512 containing a pair of holes 1512a, 1512 b is provided. As shown, the holes from this di-electric spacer1512 is in alignment with the pairs of mutually aligned holes 1508 a,1510 a and 1508 b, 1510 b from the first and second bars 1502 and 1504respectively. A first pair of terminals 1514 a, 1514 b are disposed onthe di-electric spacer 1512. A second pair of terminals 1514 c, 1514 dis disposed on the non-conducting surface 1502 b of the first bar 1502.The terminals 1514 a-1514 d are configured to be coupled tocorresponding ones of conductors 1516 a-1516 d disposed on thenon-conducting surface 1502 b of the first bar. Each terminal 1514a-1514 d has a hole 1518 a-1518 d that is disposed in mutual alignmentwith the holes 1508 a, 1510 a and 1508 b, 1510 b from respective ones ofthe first and second bars 1502, 1504 and the holes 1512 a, 1512 b of thedi-electric spacer 1512 respectively. This way, a pair of securingarrangements 1520 comprising a pair of bolts 1522 a-1522 b can bereceived within the mutually aligned holes 1508 a, 1510 a, 1512 a, 1518a and 1508 b, 1510 b, 1512 b, 1518 b from respective ones of the firstbar 1502, the second bar 1504, the di-electric spacer 1512 andcorresponding pairs of terminals 1514 a-1514 d. The securingarrangements 1520 also include a pair of nuts 1524 a-1524 bcorresponding to the pair of bolts 1522 a-1522 b and can releasablyengage with the pair of bolts 1522 a-1522 b to secure a first section1503 and a second section 1505 of the backbone 1500.

FIG. 16 illustrates a backbone section 1600 and a compound washer 1604according to an embodiment. The backbone section 1600 includes a bar1606 that is configured to define a cut-out portion 1608 therein. Thecompound washer 1604 is disposed on the bar 1606 and located about thecut-out portion 1608. The compound washer 1604 is adhered to the bar1606 with an insulating adhesive. The compound washer 604 is configuredto include a di-electric base 1610. A first ring washer 1612 is disposedon an inner circumference of the di-electric base 1610 and configured todefine a first terminal 1614. A second ring washer 1616 isconcentrically disposed about the di-electric base 1610 and is hence,located in a spaced-apart relation to the first ring washer 1612. Thedi-electric base 1610 is configured to electrically insulate the firstand second ring washers 1612, 1616 from one another. The second ringwasher 1616 is configured to define a second terminal 1618.

End portions 1620 a, 1622 a of a pair of conductors 1620, 1622 may besoldered or welded to the first and second terminals 1614, 1618respectively. Similarly, end portions 1624 a, 1626 a of another pair ofconductors 1624, 1626 may be soldered or welded to the first and secondterminals 1614, 1618 respectively. Therefore, the pair of conductors1620, 1622 are connected to the pair of conductors 1624, 1626 with thehelp of the terminals 1614, 1618 vis-à-vis the corresponding pairs ofend portions 1620 a, 1622 a and 1624 a, 1626 a from the pairs ofconductors 1620, 1622 and 1624, 1626 respectively. Each of theconductors 1620, 1622, 1624, 1626 also include an insulating sheathingmember 1628 that can be affixed to the bar 1606, for example, using anadhesive.

FIG. 17a illustrates a compound washer 1704 according to an embodiment.According to this embodiment, the compound washer 1704 includes anannular di-electric base 1706 that is disposed about a cut-out portion1708 of a bar 1702 and affixed to the bar 1702, for example, with thehelp of an adhesive. A first arcuate washer 1712 is disposed on theannular base 1706 and is configured to define a first terminal 1714. Asecond arcuate washer 1716 is disposed on the annular base 1706 andlocated in a spaced-apart relation to the first arcuate washer 1712. Thesecond arcuate washer 1716 is configured to define a second terminal1718.

Referring to FIGS. 17b and 17c , end portions 1720 a, 1722 a of a pairof conductors 1720, 1722 could be soldered to the first and secondterminals 1714, 1718 respectively. Similarly, end portions 1724 a, 1726a of another pair of conductors 1724, 1726 could be soldered to thefirst and second terminals 1714, 1718 respectively. Therefore, the pairof conductors 1720, 1722 are connected to the pair of conductors 1724,1726 with the help of the terminals 1714, 1718 vis-à-vis thecorresponding pairs of end portions 1720 a, 1722 a and 1724 a, 1726 afrom the pairs of conductors 1720, 1722 and 1724, 1726 respectively.Each of the conductors 1720, 1722, 1724, 1726 also include an insulatingsheathing member 1728 that can be affixed to the bar 1706, for example,using an adhesive.

As shown in FIG. 17b , the backbone section 1700 may include a flexplate 1728 having a pair of conducting portions 1728, 1730 that areconfigured to correspond with the pair of terminals 1714, 1718 providedon the compound washer 1704 respectively. The pair of conductingportions 1714, 1718 on the flex plate 1728 is adapted to tap power fromthe pair of terminals 1714, 1718 and route such tapped power in adirection D laterally away from a longitudinal axis AA′ of the bar 1702.In this embodiment, the backbone section 1700 would additionally includea Belleville washer 1734 and a bolt 1736 for securing the flex plate1728 to the bar 1702.

Preferentially, the backbone is as continuous as possible to ensure thatthat as few discontinuities (such as an impedance discontinuity) exist.In certain embodiments, the backbone extends from the battery 180 incontinuous segments. For example, as shown in FIG. 1b , two of segments112 are implemented as backbone to backbone connections while foursegments 112 may be used without any backbone to backbone connections,only backbone-to-battery connections.

Windowing and Backbone Connector

When backbone 112 is not formed of multiple preformed segments connectedto one another, tap-off or branch-off connections to the backbone mustbe made in another fashion. FIG. 18a illustrates a view of a backbonecable 112 that has been windowed (pocketed on one face) to allow for theconnection of the backbone cable 112 to another cable (not shown), suchas an umbilical cable 184 (see FIG. 1b ), at a location along thebackbone 112 other than the end of the backbone 112.

As shown in FIG. 18a , windows have been formed by removing the outersheathing and any other necessary layers to expose the desired layer.The 2D layout of windows may differ from that shown in FIG. 18a . FIG.18a shows a trace window 1806 that exposes conductors, such asconductors 128 c and 128 d shown in FIG. 6a or FIG. 7. When creatingthis window, not only must the outer sheathing be removed, but also anyinner sheathing and shielding layers also be removed to expose theconductors and remove any residual sheathing or adhesive residues.Shielding window 1804 is formed by removing the layers above theshielding layer. In certain embodiments, only the outer sheathing layermust be removed. Conductor windows 1808 and 1810 are similarly formed byremoving the material above the conductors to expose them. For example,conductors 128 a and 128 b as shown in FIGS. 6a and 7 are exposed byremoving part of shielding layer 132, part of inner sheathing material130 a, and part of outer sheathing material 140. The outer sheathingmaterial, which is removed to create the windows, may be PE, PP, PET,PEN, PI, another insulating material, or another polymer material. Theinner sheathing material may be PE, PP, PET, PEN, PI, another insulatingmaterial, or another polymer material. As shown in FIG. 18a , thebackbone 112 contains alignment holes 1802 near the area where theconnection to the backbone 112 is going to be made i.e., proximal to alocation of the windows 1804, 1806, 1808 and 1810. In an embodiment asshown in FIG. 18a , two alignment holes 1802 are made. However, in someembodiments, fewer or more alignment holes 1802 may be present invarying shapes and sizes, while in other embodiments, no alignment holesmay be defined.

The exposed conductors 128 a-d and shielding layer 132 from the backbonecable 112, may be connected to another backbone cable, such as anumbilical cable 184 via a connector, such as a backbone connector 190 asshown in FIG. 2. Because one or more of the conductors may becommunication lines running next to a DC power line, transmitting at forexample 48V, the communication lines and consequently, the backboneconnector 190 should be shielded. In embodiments, the assembled backboneconnector 190 meets IP67 ingress protection. In embodiments, theassembled backbone connector 190 provides shielding of up to 40 dB forelectromagnetic interference (EMI) at frequencies up to 100 MHz. Inother embodiments, the assembled backbone connector 190 providesshielding of up to 60 dB for EMI at frequencies between 100 MHz and 500MHz.

FIG. 18b illustrates windowed regions on various conductors that areincluded in the backbone section 112 of FIG. 6c . As shown, trace window1803 is created by removing a portion of the outer sheathing member 140(refer to FIG. 6c ) to expose the conductive shield member 131associated with the set of conductors 128 e-f. Similarly, trace window1806 is created by removing a portion of the outer sheathing member 140to expose the conductive shield member 131 associated with the set ofconductors 128 c-d. Trace window 1804 is created by removing adjoiningportions from the outer sheathing member 140, the conductive shieldmember 131, and the inner sheathing member 130 a to expose conductors128 c-d. Trace windows 1808, 1810, 1812 are created by removing of aportion of the outer sheathing member 140 adjacent to each of conductors128 a, 128 b, and 128 g-r, so that the set of conductors 128 a, 128 b,and 128 g-r are exposed. The exposed portions of each of conductors 128a-r and the conductive shield member 131 associated with the conductors128 e-f are then connected with the backbone section 112, for examplevia the PCBA 196 according to certain embodiments, such as those shownin FIGS. 19a-d . In embodiments, the exposed conductors and shieldingare directly connected to corresponding conductors or shielding in anumbilical cable 184. In certain embodiments, when umbilical cable 184has fewer conductors than the backbone section 112, then a window (andsubsequent connection) need to be created. For example, if umbilicalcable 184 only has two of conductors 128 g-r (specifically, conductors128 g-h), then only two trace windows 1812, those exposing conductors128 g-h, need be created, and subsequently, only conductors 128 g-h inthe backbone section are connected to conductors 128 g-h in theumbilical cable 184.

In embodiments the size of the window (width and height of the exposedconductors or shielding) varies depending on the width of the underlyingconductors or underlying conductive shield member 131. Further, as shownin FIG. 18b windows may be offset from one another to facilitateconnection to the underlying conductor or shielding. This decreases thepossibility that two or more conductors, for example 128 g-r) willinadvertently connect, creating a short. While adjacent windows 1312 areshown in FIG. 18b to be offset from one another, this offset may not berequired, for example, when the PCBA 196.

FIG. 19a shows an exploded view of the backbone connector 190 accordingto certain embodiments of the current invention and FIG. 19b shows thesame connector 190 closed, connecting a backbone section 112 to anumbilical cable 184. As shown in FIG. 19a , the backbone connector 190has a base plate 192 that may be formed via plastic injection molding oranother molding technique. Base plate 192 may be formed from PE, PP,PET, PBT, Nylon or another polymer. In other embodiments, base plate 192is a formed of a metallic or a ceramic material. Backbone connector 190has posts 198 protruding from the base plate 192. These posts 198 maynot be part of the mold, but may be externally attached as a secondaryoperation. They may also help align backbone section 112. The other sideof backbone connector 190 is PCBA 196, which is connected to umbilicalcable 184. PCBA 196 and umbilical cable 184 may be hot bar soldered,laser or ultrasonically soldered, adhered using an adhesive, orconnected via another method such as Anisotropically Conductive Films orPastes (ACFs or ACPs). Excluding connectors is desirable from a costperspective since it removes a connector, driving down cost. PCBA 196also preferentially has alignment holes that are configured to acceptposts 198 for alignment and retention purposes. The addition of nuts 199forms the backbone connector 190 and allows for an electrical connectionto be made from the backbone section 112 to the umbilical cable 184 whenthe backbone connector 190 is closed as shown in FIG. 19b . Torqueresulting from a tightening of the nuts 199 with the posts 198 alsoallows for a proper seal to the exposed windows using ingress protector194. The seal prevents dust and water from entering into the backboneconnector 190, whether through leak paths along the nuts 199 or alongthe edges of the base plate 192, and shorting any connections orotherwise decreasing lifetime. In embodiments, the PCBA 196 routes datasignals and the desired amount of voltage to the appropriate location.

In certain embodiments, posts 198 are part of the base plate 192 andmolded together as one part. In other embodiments, the posts 198 areseparate from the base plate 192, as shown in FIG. 19c . FIG. 19c alsoshows a mounting adhesive 2110 affixed to a rear of the base plate 192,according to certain embodiments. Mounting adhesive 2110 allows for thebackbone connector 190 to be affixed to a desired location, such as aspecific location in a vehicle. Mounting adhesive 2110 may be ofacrylic, epoxy, or silicone types, or hybrid adhesives of complexformulations. FIG. 19d shows part of the assembled backbone connector190 with separate posts 198 (that is posts 198 that are not integrallyformed with the base plate 192 as shown in FIG. 19c ) and ingressprotector 194 positioned on top of the base plate 192.

In embodiments, spring fingers 2210 are affixed to the PCBA 196 as shownin the exploded view of FIG. 20a and the non-exploded view of FIG. 20b .Spring fingers 2210 may be of Copper (Cu) or Aluminum (Al) and may beplated with tin (Sn), nickel (Ni), gold (Au), or another conductivematerial. In other embodiments, spring fingers 2210 may be replaced withPogo pins (not shown) or other element with a similar “face-contact”mechanism. Also shown in FIG. 20a is (1) adhesive seal 2220 that helpsadhere the umbilical cable 184 to the PCBA 196, (2) EMI shield gasket195 that helps shield conductors used to transmit data signals, such asconductors 128 c and 128 d shown in FIGS. 6a and 7, and (3) gasket seal197, which helps prevent any dust or water vapor from entering andshorting out the electrical connections. EMI shield gasket 195 may bemade of a metal foam, a conductive polymer, or another material(preferably conductive) that shields certain conductors carrying datasignals from electrical noise. Additionally, the PCBA 196 may havepassive or active electrical components (such as MOSFETS, resistors,op-amps, or microcontrollers) for added performance and control.Consequently, heat sinks (not shown) and other thermal dissipation meansmay also become part of the backbone connector 190.

FIGS. 21-24 illustrate the installation procedure of connecting abackbone section 112 to an umbilical cable 184 using a backboneconnector 190 according to an embodiment of the current invention. Asshown in FIG. 21, base plate 192 with posts 198 is installed in thevehicle (using adhesive or otherwise). As shown in FIG. 22, backbonesection 112 is installed over the posts 198. Alternatively, backbonesection 112 could have already have been joined to base plate 192 withposts 198 prior to base plate 192 being installed onto vehicle. As shownin FIG. 23, the PCBA 196 with attached umbilical cable 184 is alignedover posts 198. In certain embodiments, the PCBA 196 includes springfingers 2210, EMI shield gasket 195 and gasket seal 197 as shown inFIGS. 20a-20b . Referring now to FIG. 24, nuts 199 are attached tosecure the PCBA 196 to the base plate 192 and form the electricalconnections between backbone 112 and umbilical cable 184. FIG. 25illustrates a cross section view of the backbone connector 190 accordingto an embodiment of the current invention. Spring fingers 2210, baseplate 192, posts 198, nuts 199, PCBA 196, and other components areshown.

FIGS. 26-28 illustrate another embodiment of the backbone connector 190.FIGS. 26 and 27 show an exploded view of the backbone connector 190.Base plate 192 has a conductive gasket 2620 that when closed helps sealthe backbone connector 190 from the environment, including dust andwater vapor, as well as provide shielding from EMI for frequenciesbetween 100 MHz to 500 MHz. In certain embodiments, the assembledbackbone connector 190 meets IP67 ingress protection. Upper cover 2610has snap hooks 2614 and pins 2612. Pins 2612 help align the backbonesection 112 and umbilical cable 184 that is connected to PCBA 196, aswell as the upper cover 2610 with the base plate 192. Upper cover 2610may contain a conductive surface 2750 on the inside, such as a metal orconductive polymer coating. In other embodiments, the outside of theupper cover 2610 is the conductive surface or the upper cover 2610 ismade from a conductive material, such as a metal, conductive polymer, orinsulating material dispersed with metal particles (such as silvernanoparticles or Al deposition using vacuum metallization). In certainembodiments, upper cover 2610 is molded. Base plate 192 may also containa conductive surface on the top side, such as a metal or conductivepolymer coating. In other embodiments, the bottom of the base plate 192is the conductive surface or the base plate 192 is made from aconductive material, such as a metal, conductive polymer, or insulatingmaterial dispersed with metal particles (such as silver nanoparticles).In certain embodiments, base plate 192 is molded. FIG. 28 shows thebackbone connector 190 fully assembled connecting backbone section 112to umbilical cable 184. In embodiments, the PCBA 196 routes data signalsand the desired amount of voltage to the appropriate location and maycontain active or passive electrical components (such as MOSFETS,resistors, op-amps, or microcontrollers)

FIGS. 29-31 illustrate another embodiment of the backbone connector 190.FIGS. 29 and 30 show an exploded view of the backbone connector 190.Base plate 192 has pins 2912 to help align the connection between thebackbone section 112 and umbilical cable 184. Base plate 192 alsocontains a snap feature 3012, preferably around the entire perimeter.Upper cover 2910 has alignment holes 2914, which are configured toaccept pins 2912 from base plate 192. When assembled, as shown in FIG.31, backbone connector 190 seals the PCBA 196 and windowed backbone 112from the environment, including dust and water vapor. In certainembodiments, the assembled backbone connector 190 meets IP67 ingressprotection. Upper cover 2910 may contain a conductive surface on theinside, such as a metal or conductive polymer coating. In otherembodiments, the outside of the upper cover 2910 is the conductivesurface or the upper cover 2910 is made from a conductive material, suchas a metal, conductive polymer, or insulating material dispersed withmetal particles (such as silver nanoparticles). In certain embodiments,upper cover 2910 is molded. Base plate 192 may also contain a conductivesurface on the top side, such as a metal or conductive polymer coating.In other embodiments, the bottom of the base plate 192 is the conductivesurface or the base plate 192 is made from a conductive material, suchas a metal, conductive polymer, or insulating material dispersed withmetal particles (such as silver nanoparticles). In certain embodiments,base plate 192 is molded. FIG. 31 shows the backbone connector 190 fullyassembled connecting backbone section 112 to umbilical cable 184. Inembodiments, the PCBA 196 routes data signals and the desired amount ofvoltage to the appropriate location and may contain active or passiveelectrical components (such as MOSFETS, resistors, op-amps, ormicrocontrollers)

The foregoing disclosure is not intended to limit the present disclosureto the precise forms or particular fields of use disclosed. As such, itis contemplated that various alternative embodiments and/ormodifications to the present disclosure, whether explicitly described orimplied herein, are possible in light of the disclosure. Having thusdescribed embodiments of the present disclosure, a person of ordinaryskill in the art will recognize that changes may be made in form anddetail without departing from the scope of the present disclosure. Forexample, reference is made to “wire” or “wires,” but a person ofordinary skill in the art will understand that in certain embodiments,one or more conductors (for example, metal without any insulation orouter sheathing) may be substituted. Thus, the present disclosure islimited only by the claims.

In the foregoing specification, the disclosure has been described withreference to specific embodiments. However, as one skilled in the artwill appreciate, various embodiments disclosed herein can be modified orotherwise implemented in various other ways without departing from thespirit and scope of the disclosure. Accordingly, this description is tobe considered as illustrative and is for the purpose of teaching thoseskilled in the art the manner of making and using various embodiments ofthe present disclosure. It is to be understood that the forms ofdisclosure herein shown and described are to be taken as representativeembodiments. Equivalent elements, or materials may be substituted forthose representatively illustrated and described herein. Moreover,certain features of the disclosure may be utilized independently of theuse of other features, all as would be apparent to one skilled in theart after having the benefit of this description of the disclosure.Expressions such as “including”, “comprising”, “incorporating”,“consisting of”, “have”, “is” used to describe and claim the presentdisclosure are intended to be construed in a non-exclusive manner,namely allowing for items, components or elements not explicitlydescribed also to be present. Reference to the singular is also to beconstrued to relate to the plural.

Further, various embodiments disclosed herein are to be taken in theillustrative and explanatory sense, and should in no way be construed aslimiting of the present disclosure. All joinder references (e.g.,attached, affixed, coupled, connected, and the like) are only used toaid the reader's understanding of the present disclosure, and may notcreate limitations, particularly as to the position, orientation, or useof the systems and/or methods disclosed herein. Therefore, joinderreferences, if any, are to be construed broadly. Moreover, such joinderreferences do not necessarily infer that two elements are directlyconnected to each other.

Additionally, all numerical terms, such as, but not limited to, “first”,“second”, “third”, “primary”, “secondary”, “main” or any other ordinaryand/or numerical terms, should also be taken only as identifiers, toassist the reader's understanding of the various elements, embodiments,variations and/or modifications of the present disclosure, and may notcreate any limitations, particularly as to the order, or preference, ofany element, embodiment, variation and/or modification relative to, orover, another element, embodiment, variation and/or modification.

It will also be appreciated that one or more of the elements depicted inthe drawings/figures can also be implemented in a more separated orintegrated manner, or even removed or rendered as inoperable in certaincases, as is useful in accordance with a particular application.

What is claimed is:
 1. A backbone section comprising: an outersheathing; a first conductor disposed within the outer sheathing,wherein the first conductor is adjacent to a first wall of the outersheathing; a second conductor disposed within the outer sheathing,wherein the second conductor is adjacent to a second wall of the outersheathing, the second wall opposite the first wall of the outersheathing; a pair of inner sheathing members disposed within the outersheathing, one end of the pair of inner sheathing members disposedadjacent to the first wall of the outer sheathing and an opposite end ofthe pair of inner sheathing extending away from the first wallperpendicularly, the inner sheathing members located on opposing sidesof at least one of the first and second conductors, the pair of innersheathing members configured to electrically insulate the firstconductor and the second conductor; and a shield member disposed withinthe outer sheathing.
 2. A backbone connector comprising: a base plate; asheathed conductor comprising a sheath and one or more conductors,wherein the sheath encompasses the one or more conductors; a PCBA itselfcomprising a seal gasket and EMI shield, the PCBA configured toelectrically connect to the one or more conductors; at least one windowcomprising a hole cut into the sheath of the sheathed conductor toexpose at least one of the one or more conductors, wherein the one ormore conductors are configured to electrically connect to the PCBAthrough the window; and multiple posts each engaged with a nut to holdthe PCBA to the base plate, wherein the multiple posts align the baseplate, sheathed conductor, and the PCBA and electrically connect the oneor more conductors of the sheathed conductor and the PCBA.
 3. Thebackbone connector of claim 2 wherein the multiple posts areincorporated into the base plate in a single piece.
 4. The backboneconnector of claim 3 wherein the EMI shield comprises a conductivepolymer.
 5. The backbone connector of claim 3 wherein the EMI shieldcomprises metallic nanoparticles dispersed within a polymeric matrix. 6.A backbone connector comprising: a base plate; a tentacle cablecomprising a sheath and one or more conductors, wherein the sheathencompasses the one or more conductors; a PCBA attached to an umbilicalcable, wherein the PCBA is configured to electrically connect to thetentacle cable; at least one window, a window comprising a cut into thesheath of the tentacle cable, wherein at least one of the one or more ofthe one or more conductors is exposed by the at least one window; anupper cover; and multiple posts that hold and align the base plate,tentacle cable, and the PCBA attached to the umbilical cable, whereinthe alignment makes the electrical connection between the tentacle cableand the PCBA through the at least one window.
 7. The backbone connectorof claim 6, wherein the upper cover comprises a receptacle ring.
 8. Thebackbone connector of claim 6, wherein the base plate further comprisesa sealing gasket and the multiple posts.
 9. The backbone connector ofclaim 6, wherein the upper cover comprises the multiple posts, a shieldlayer made of a conductive material, and a gasket.
 10. The backboneconnector of claim 9, wherein the shield layer is on an exterior of theupper cover.
 11. The backbone connector of claim 9, wherein the shieldlayer is on an interior of the upper cover.
 12. The backbone connectorof claim 9, wherein the gasket is made of a conductive material.
 13. Amethod of assembling a backbone connector to connect a backbone sectionto an umbilical cable in a vehicle, comprising: installing a base plateto a location in the vehicle, wherein the base plate comprises multipleposts; installing a sheathed conductor comprising a sheath and one ormore conductors, wherein the sheath encompasses the one or moreconductors; installing at least one window on the sheathed conductor,the window comprising a hole cut into the sheath of the sheathedconductor to expose at least one of the one or more conductors;installing the backbone section that contains an alignment hole suchthat the alignment hole aligns with one or more of the multiple posts;installing a PCBA over the multiple posts such that at least a portionof the posts passes through the PCBA, the PCBA configured toelectrically connect to the one or more conductors through the window;and attaching nuts to the posts for securing the PCBA to the base plate.14. The method of claim 13, wherein after the nuts have secured the PCBAto the base plate, the assembled backbone connector meets IP67 ingressprotection.
 15. A method of assembling a backbone connector to connect abackbone section to an umbilical cable in a vehicle, comprising:installing a base plate to a location in the vehicle, the base platecomprising multiple posts; installing a sheathed conductor comprising asheath and one or more conductors, wherein the sheath encompasses theone or more conductors; installing at least one window on the sheathedconductor, the window comprising a hole cut into the sheath of thesheathed conductor to expose at least one of the one or more conductors,wherein an electrical connection between the one or more conductors anda PCBA can be made through the window; installing the backbone sectionthat contains an alignment hole such that the alignment hole aligns withone or more of the multiple posts; installing the PCBA over the multipleposts such that at least a portion of the posts passes through the PCBA,the PCBA configured to electrically connect to the one or moreconductors; and attaching an upper cover that comprises a snapreceptacle ring and a shield layer.
 16. The method of claim 15 whereinafter nuts have secured the PCBA to the base plate, the assembledbackbone connector meets IP67 ingress protection.
 17. A method ofassembling a backbone connector to connect a backbone section to anumbilical cable in a vehicle, comprising: installing a base plate to alocation in the vehicle; installing a sheathed conductor comprising asheath and one or more conductors, wherein the sheath encompasses theone or more conductors; installing at least one window on the sheathedconductor, the window comprising a hole cut into the sheath of thesheathed conductor to expose at least one of the one or more conductors,wherein an electrical connection between the one or more conductors anda PCBA can be made through the window; installing the backbone sectionthat contains an alignment hole such that the alignment hole aligns withone or multiple posts; installing the PCBA over the multiple posts suchthat at least a portion of the posts passes through the PCBA, the PCBAconfigured to electrically connect to the one or more conductors; andattaching an upper cover that comprises multiple posts, a gasket,multiple snap hooks, and a shield layer.
 18. The method of claim 17,wherein after nuts have secured the PCBA to the base plate, theassembled backbone connector meets IP67 ingress protection.